Wintriss SmartPAC 2 - Page 2

Wintriss SmartPAC 2

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Table of Contents

Default Chapter7
- Table of Contents7
Chapter 1. Introduction29
- WPC 2000 and Control Reliability29
- Smartpac 2 with WPC 200029
- Resolver-Based Operation34
- Smartpac 2 Front Panel34
- Figure 1-1. Smartpac 2 Front Panel35
- WPC 2000 Operator Station36
- Figure 1-2. Operator Station Components (Side-Mounted Run/Inch Palm Buttons)36
- Smartpac 2 Settings37
- Sensors Available for Dipropac38
- Procampac Programmable Cams39
- Smartpac 2'S Three Modes of Operation39
- Smartpac 2 with WPC 2000 Specifications40
Chapter 2. Installation45
- Installation Guidelines47
- Figure 2-1. Installation Overview48
- Connecting Wires to Terminal Block Connectors49
- Terminating Cable Shields50
- Figure 2-2. Correct Way to Attach Wires to Terminal Block Connectors50
- Figure 2-3. Connecting Shield Drain Wire to Ground Stud50
- Checking the Press51
- Installing WPC 200051
- Installing WPC 2000 Options78
- Installing Smartpac 291
- Installing Smartpac 2 Options100
Wiring Diagrams105
- Table 2-19. Dipro Sensor Interface (DSI) 2 to Smartpac 2 Wiring, Sensors 9-16106
- Setting up Smartpac 2 with WPC 2000115
- Installing Revised Firmware in WPC 2000129
- Performing Checkout Tests131
- What Next157
- Wiring Tables157
- Table 2-27. WPC 2000 Main Processor Board, TB101-TB104: Wiring Connections158
- Table 2-28. WPC 2000 Power Supply (TB105) Wiring Connections159
- Table 2-34. Smartpac 2 Spare 1 Port (5) and WPC Port (6) (TB105) Wiring Connections160
Chapter 3. Smartpac 2 Keyboard, Displays and Operating Modes161
- Comparing Smartpac 2 with Original Smartpac162
- Smartpac 2 Keyboard163
- Smartpac 2 Display Layout in Run Mode173
  - Selecting an Item on a Display174
- Smartpac 2 Operating Modes175
- Screen Capture183
  - Screen Capture in Smartpac 2 Main Versions Earlier than V 5.3.1183
  - Screen Capture in Smartpac 2 Main Versions V 5.3.1 and Later185
Chapter 4. Smartpac 2 Initialization Mode187
- Entering and Exiting Initialization Mode188
- Initializing WPC 2000 Parameters189
- Resolver Zero189
  - Moving the Ram to Top Dead Center (TDC)189
  - Setting the Resolver Zero Position190
- Position Sensor191
  - Position Sensor Mode191
  - Resolver Motion Mode (Normal Motion - Link Motion)192
  - Angle Wheel Rotation (Clockwise - Counterclockwise)192
  - Tool Number Mode192
  - Table 4-2. Numeric and Alphanumeric Tool Number Modes193
  - Counter Setup Mode194
  - Counter Increment Mode194
- Installed Options195
- Press Name196
- SELECT CAM NAMES (Optional)196
- Figure 4-7. Cam Channel Name Menu (16-Channel Procampac)197
- AUTO ADVANCE and Slow RPM (Optional)198
  - Calculating the Auto Advance Constant199
  - Setting Auto Advance Constants and Slow RPM200
- SET GLOBAL CAMS (Optional)201
- Figure 4-10. Global Cams Menu202
- CUSTOM SENSOR NAMES (Optional)203
- SENSOR ENABLE MODE (Optional)204
  - Selecting Sensor Enable Mode204
  - Enabling Setup Mode205
- Tool Information205
- Figure 4-14. Tool Information Setup Screen206
- Figure 4-16. Tool Information Units Selection Screen207
- Table 4-3. Abbreviations for Units on Tool Information Setup Screen208
- Press Control209
  - User Interlocks210
  - Figure 4-20. Select Stop Name Screen212
  - Press Parameters213
  - Figure 4-22. Initialize Parameters Warning Message220
  - Press Options221
  - Table 4-11. Switch 8 Settings (S101): Top-Stop Mode for F and H Errors225
  - Table 4-12. Switch 8 Settings (S101): Auxiliary Output 1 Response to Interrupted Stroke226
  - Figure 4-24. S102 Option Switch off and on Settings228
  - Table 4-14. Switch 6 Settings (S102): Selecting Concurrent Time for Multiple Op. Stations229
  - Input Status230
  - Figure 4-26. WPC Buttons and Switches Input Status Screen231
  - Figure 4-28. WPC Interlock Group 1 Input Status Screen232
- Security Access233
  - Table 4-15. Security Access Settings234
  - Setting Security Access235
  - Changing Passwords236
  - Figure 4-32. Set Passwords Menu237
  - Additional Security238
- Backup/Restore238
  - Backing up Tools to a USB Disk238
  - Figure 4-34. Backup/Restore Control Menu239
  - Restoring Tools from a USB Disk240
- SETUP DATA COMMS (Optional)241
- Setup Network242
  - E-Mail Function243
  - Smartview Function244
  - Setup E-Mail244
  - Figure 4-39. Alphanumeric Entry Window with Default Mail Server Displayed245
  - Change Network Settings246
  - Press Type246
- Diagnostics247
  - Communications248
  - Set Clock250
  - Save to Usb Disk251
  - Update Firmware251
- Using Smartpac 2 with a Link-Motion Press251
  - Setting Link Motion252
  - Using a Servofeed Interface with Link Motion252
- Using a Computer Keyboard to Enter Names254
Chapter 5. Smartpac 2 Program Mode255
- Entering and Exiting Program Mode255
- Tool Manager256
- Tool Program Menu262
- TOOL NAME or TOOL ID262
- Counters263
- DIE PROTECTION (Optional)270
- CAM SWITCH (Optional)292
- Press Control302
- Figure 5-56. Press Control Parameters Screen303
- Tool Information304
- Figure 5-58. Tool Information Screen305
- SENSOR ENABLE/DISABLE & STATUS (Optional)306
Chapter 6. Smartpac 2 Run Mode309
- Entering and Exiting Run Mode310
- Loading a Tool310
- Programming Hot Keys311
- Settings Locked, or Password Required312
- Displaying Multiple Faults313
- Opening the Crankshaft Angle Window314
- Disable (Enable) Sensors314
- Figure 6-8. Main Run Menu with SENSORS ENABLED Display315
- Counters316
- DIE PROTECTION (Optional)317
  - Figure 6-12. die Protection Menu (Run Mode)318
  - Adjusting the Ready Signal for Green Sensors319
  - Adjusting the Stroke Preset for Green Special Sensors321
  - Viewing the Sensor Summary321
  - Show Sensor Status322
  - Adjusting Dipropac 32 Sensors323
  - Figure 6-17. die Protection Sensor Menu for Sensors 17-32324
  - Figure 6-19. Green Special Sensor Stroke Count Screen, Run Mode325
- CAM SWITCH (Optional)326
  - Viewing Cam Timing327
  - Viewing the Global Cam Summary328
  - Viewing the Cam Summary328
- Brake Monitor328
  - Determining the Stopping Time of Your Press329
  - Performing the 90× Stop-Time Test330
  - Calculating the Safety Distance331
  - Table 6-2. Shadow Light Curtain Response Time and Object Sensitivity333
- Press Control338
  - Adjusting Program Settings338
  - Figure 6-24. Press Control Parameters Screen339
  - Displaying Overrun Sensor On/Off Angles340
- Tool Information341
- Error/Event Log342
- Load New Tool343
- Figure 6-28. Tool Manager Screen344
- Messaging345
  - Sending E-Mail to Wintriss Technical Support346
- Toggle Hot Keys347
- Operating the Press347
  - Responding to an Interrupted Stroke347
  - Selecting Operating Mode348
  - Operating the Press in Inch Mode349
  - Operating the Press in Single-Stroke Mode351
  - Operating the Press in Automatic Single-Stroke Mode357
  - Operating the Press in Continuous Mode358
  - Operating the Press in Automatic Continuous On-Demand Mode360
  - Operating the Press in Bar Mode361
  - Multiple Operator Stations362
Chapter 7. Fault Messages363
- Responding to Fault Messages364
- Lockout Message365
- Brake Monitor Faults365
  - Brake Warning LED365
  - Stop Time Exceeded365
- Messages for Press Control Problems367
- Counter Preset Reached Messages385
- Messages for Equipment or Brake Monitor Problems386
- Messages for Programming Problems389
- Messages for Sensor Faults390
- Miscellaneous Fault Messages392
- Troubleshooting Using the Error/Event Log393
- Resetting Ross DM2 DSV Faults393
- Figure 7-4. Ross DM2 DSV Showing Reset Button394
Appendix A. Extracts from OSHA Regulations and ANSI395
Standards395
- Controls399
Appendix B. Specifications for User-Built Operator Stations413
- Run Button Installation413
- Switch Requirements414
Appendix C. Smartpac Preventive Maintenance (PM) Monitor415
- About Smartpac PM Monitor415
- Installing the PM Monitor417
  - For New Systems from the Factory417
  - For Existing Systems417
- Using the PM Monitor in Initialization Mode418
- Using the PM Monitor in Run Mode426
Appendix D. Updating Smartpac 2 Firmware429
- Updating Firmware Using a USB Disk429
- Installing Firmware from a Replacement Compact Flash (CF) Card437
- Figure D-5. Firmware Load Menu with "RELOAD CURRENT FIRMWARE" Highlighted438
- Figure D-7. Smartpac 2 Display with "Loading Firmware" Message439
Appendix E. Smartview Remote Viewing and E-Mail Setup441
- Network Requirements441
- Network Setup441
- Table E-1. Smartpac 2 Board: PS 2 and Y-Cable Configuration444
- Installing Smartview446
- Smartview Operation450
- Remote Messaging453
- E-Mail Setup454
- Smartview Ping Utility455
- Figure E-12. Mabry Internet Ping Window456
- Figure E-14. Ping Utility Window with Example of a Successful Ping457
Appendix F. Upgrading from Original Smartpac to Smartpac 2459
- Backing up Tools on Original Smartpac459
- Figure F-1. Backup/Restore Control Menu460
- Removing Smartpac 1 and Mounting Smartpac 2461
- Wiring the Smartpac 2462
- Table F-13. Smartpac 1 to Smartpac 2 Wiring Changes: Remote Reset (Optional)468
- Table F-15. Smartpac 1 to Smartpac 2 Wiring Changes: SFI (Optional)469
  - AC Wiring on Smartpac 2470
- Restoring Tools to Smartpac 2470
- Figure F-3. Backup/Restore Control Menu with Restore Confirmation Message Displayed471
- System Checkout472
Appendix G. Replacing Smartpac 2 PC Board473
- Unpacking the Replacement Board473
- Installing the Replacement Board474
- Figure G-1. Smartpac 2 PC Board475
- Figure G-2. Firmware Load Menu with "RELOAD CURRENT FIRMWARE" Highlighted477
Appendix H. Reporting Downtime and Scrap to SFC479
- Machine States to Which SFC Logs Press Time479
- Smartpac 2 Downtime Reporting Features480
- Setting up Smartpac 2 to Report Downtime485
  - Making Downtime Reporting Settings485
  - Figure H-4. Smartpac 2 Main Initialization Menu486
- Table H-1. Set Communications Menu Settings487
- Documenting Downtime on the Dialog Menu494
- Reporting Scrap and Good Parts to SFC500
Appendix I. Reporting Downtime and Scrap to LETS505
- Machine States to Which LETS Logs Press Time505
- Smartpac 2 Downtime Reporting Features506
- Setting up Smartpac 2 to Report Downtime510
- Documenting Downtime on the Dialog Menu518
- Reporting Scrap and Good Parts to LETS523
Appendix J. Option 1 User Inputs529
- Table J-1. Option 1 User Inputs: Input Type and Stop Type530
- Installing the Option 1 Board531
- Figure J-1. Option 1 Board Installed on WPC 2000 Main Processor Board532
- Wiring Option 1 User Inputs533
  - Table J-2. WPC 2000 Option 1 Board: Wiring Connections, TB601534
  - Figure J-3. WPC 2000 Option 1 Board: LED Map535
- Changing User Input Stop Type536
- Viewing the Status of User Inputs537
- Troubleshooting538
- Option 1 User Input Setup Sheet540
Glossary541
Index557

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